Deflatable inflatable web

ABSTRACT

A protective packaging web is disclosed. The web includes a flexible inflatable web that includes inflatable chambers having inlets and configured for receiving a fluid from the inlets and sealing the fluid therein, the inflatable chambers being configured such that, when inflated, the inflatable web structure has a first contoured exterior surface including a plurality of peaks and valleys, and a flexible first outer ply affixed to the peaks and detached from the valleys of the first contoured surface, such that when the inflatable chambers are inflated, the first outer ply extends along a phantom first tangential surface, bridging the valleys of the first contoured surface, such that when the chambers are inflated the affixed first outer ply and the inflatable web cooperatively form a framed structure having significantly elevated bending stiffness compared to a bending stiffness resulting from the inflatable web structure absent the attached first outer ply.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No.62/946,826, filed Dec. 11, 2019, the disclosure of which is incorporatedherein by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to inflatable cushioningmaterial for packaging and shipping and, more specifically, to packaginghaving plastically deformed chambers that are inflatable after formationof the material.

BACKGROUND

A traditional type of protective packaging is known as bubble wrap.Bubble wrap is made with a flexible plastic film in which caps arevacuum formed. This film is sealed to another, flat, flexible plasticfilm around the perimeters of the caps to isolate and seal the cavityformed by the caps, trapping air therein, and providing a low density,protective packaging sheet. Some bubble wrap is produced by sealingflat, flexible plastic film onto the caps on the opposite side of theother flat film, and is often referred to as “third web bubble” and usedfor making padded envelopes, for example. Bubble wrap, however, oncemanufactured, must also be transported to sites in its bulky,low-density configuration, making it volumetrically inefficient totransport to the packaging sites.

SUMMARY

According to an aspect of the present disclosure, a protective packagingweb is provided. The web includes a flexible inflatable web thatincludes inflatable chambers having inlets and configured for receivinga fluid from the inlets and sealing the fluid therein, the inflatablechambers being configured such that, when inflated, the inflatable webstructure has a first contoured exterior surface including a pluralityof peaks and valleys, with the peaks defining a phantom first tangentialsurface connecting the plurality of peaks. The web further includes aflexible first outer ply affixed to the peaks and detached from thevalleys of the first contoured surface, such that when the inflatablechambers are inflated, the first outer ply extends along the phantomfirst tangential surface, bridging the valleys of the first contouredsurface, such that when the chambers are inflated the affixed firstouter ply and the inflatable web cooperatively form a framed structurehaving significantly elevated bending stiffness compared to a bendingstiffness resulting from the inflatable web structure absent theattached first outer ply.

In certain embodiments, the inflatable web structure can include firstand second overlayed chamber plies with a seal pattern therebetween thatprovides the contoured surface when the inflatable chambers areinflated.

In certain embodiments, the first chamber ply defines the firstcontoured surface, and the second chamber ply is a second outer ply thatcooperates with the first outer ply and first chamber ply to provide theframed structure.

In certain embodiments, the second surface is configured to define asecond contoured exterior surface when the inflatable chambers areinflated on an opposite major side of the inflatable web structure fromthe first contoured surface.

In certain embodiments, the web further includes a flexible second outerply affixed to the peaks and detached from the valleys of the firstcontoured surface including a plurality of peaks and valleys, whereinthe plurality of peaks of the second contoured surface define a phantomsecond tangential surface connecting the plurality of peaks, such thatwhen the inflatable chambers are inflated, the second outer ply extendsalong the phantom second tangential surface, bridging the valleys of thesecond contoured surface, thereby cooperatively increasing the bendingstiffness of the framed structure.

In certain embodiments, a distance along the first contoured surfacebetween the peaks thereof to which the first outer ply is affixed isgreater than a distance along the first outer ply between the peaks towhich the first outer ply is affixed.

In certain embodiments, the protective packaging web with the inflatablechambers inflated has a plank configuration that is naturally biased toretain a flat configuration with the first and second outer pliesextending generally flat.

In certain embodiments, the peaks include a multitude of peaks arrangedin a 2D pattern over the first contoured surface.

In certain embodiments, the inflatable chambers include a plurality ofprotruding structures, each of the plurality of protruding structuresincluding a base perimeter enclosing an open base region and an extendedsurface protruding from a plane defined by the flexible inflatable webin a generally flat state, the protruding structures having a largersurface area than the open base region, forming a series of cavities,and each of the plurality of protruding structures includes an inflationport allowing each of the plurality of cavities to be inflated via theinflation port.

In certain embodiments, the surface of the protruding structures isformed at least in part by a plastically stretched portion of theflexible inflatable web.

In certain embodiments, each of the inflatable chambers extends alongthe flexible inflatable web at a non-perpendicular angle to alongitudinal edge of the flexible inflatable web.

In certain embodiments, the flexible inflatable web and the flexiblefirst outer ply form secondary inflatable chambers therebetween havinginlets and configured to receiving a fluid from the inlet and sealingthe fluid therein.

In certain embodiments, the web further includes one or more ventingcomponents between the flexible inflatable web and the flexible firstouter ply configured to enable fluid to be removed from the one or moresecondary inflatable chambers.

In certain embodiments, the flexible first outer ply extends along alength of the flexible inflatable web.

In certain embodiments, the web further includes a channel connecting tothe inlet, the channel forming a fluid path formed within the flexibleinflatable web, wherein the inlet allows fluid to flow out of theinflatable chambers and back into the inflatable chambers such that theinflatable chambers can be collapsed to a substantially uninflated stateand subsequently returned to an inflated state.

In certain embodiments, the inflatable chambers are configured toreceive a longitudinal seal adjacent thereto such that the longitudinalseal closes off the inlets, preventing the inflatable chambers frombeing inflated or deflated.

In certain embodiments, the flexible first outer ply is configured to beaffixed to the flexible inflatable web via heat seals.

In certain embodiments, the web further includes a heat resistivematerial affixed to one or more of the flexible first outer ply and theflexible inflatable web, wherein the heat resistive material preventsthe first outer ply to be heat sealed to the flexible inflatable web atlocations at which the heat resistive material is positioned between theflexible first outer ply and the flexible inflatable web.

According to another aspect of the present disclosure, a method forforming an inflatable web is provided. The method includes providing aflexible inflatable web that includes inflatable chambers having inletsand configured for receiving a fluid from the inlet and sealing thefluid therein, the inflatable chambers being inflated, and theinflatable web structure having a first contoured exterior surfaceincluding a plurality of peaks and valleys, with the peaks defining aphantom first tangential surface connecting the plurality of peaks, andaffixing a flexible first outer ply to the peaks of the first contouredsurface while the inflatable chambers are inflated and the inlets areyet unsealed, such that the first outer ply is detached from the valleysand the first outer ply extends along the phantom first tangentialsurface, bridging the valleys of the first contoured surface, such thatwhen the chambers are inflated the affixed first outer ply and theinflatable web cooperatively form a framed structure havingsignificantly elevated bending stiffness compared to a bending stiffnessresulting from the inflatable web structure absent the attached firstouter ply.

In certain embodiments, the method further includes holding the inletsat least partially closed to retain the fluid in the inflated chambers,wherein the first flexible ply is affixed to the peaks while the inletsare held closed.

In certain embodiments, the inlets are held closed by pinching.

In certain embodiments, the flexible outer ply is affixed to the peaksby heat sealing.

In certain embodiments, the method further includes applying a heatresistive material to one or more of the flexible first outer ply andthe flexible inflatable web, wherein the heat resistive materialprevents the first outer ply to be heat sealed to the flexibleinflatable web at locations at which the heat resistive material ispositioned between the flexible first outer ply and the flexibleinflatable web.

In certain embodiments, the contoured surface is formed at least in partby a plastically stretched portion of the first film ply.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features of the present disclosure will becomemore fully apparent from the following description and appended claims,taken in conjunction with the accompanying drawings. Understanding thatthese drawings depict only several examples in accordance with thedisclosure and are, therefore, not to be considered limiting of itsscope, the disclosure will be described with additional specificity anddetail through use of the accompanying drawings, in which:

FIG. 1A is a bottom perspective view of plies used to form an inflatableweb with inflatable sub-chambers in accordance with an embodiment;

FIG. 1B is a top view an inflatable web of FIG. 1A with inflatablesub-chambers;

FIG. 1C is a cross-section of the inflatable web of FIG. 1B with the webhaving a base ply, a formed ply, and a tertiary ply;

FIG. 1D is a cross-section of the inflatable web of FIG. 1B with the webhaving a base ply, a formed ply, and a tertiary ply;

FIG. 2A is an inflatable web with inflatable sub-chambers and a tertiaryply having openings near the edges;

FIG. 2B is a cross-section of the inflatable web of FIG. 2A;

FIG. 3A is an inflatable web with inflatable sub-chambers and aperforated tertiary ply;

FIG. 3B is a cross-section of the inflatable web of FIG. 3A;

FIG. 4A is an inflatable web having diagonally-oriented inflatablesub-chambers;

FIG. 4B is an inflatable web having diagonally-oriented inflatableorphan sub-chambers;

FIG. 4C is an inflatable web having a staggered orientation ofinflatable sub-chambers;

FIG. 4D is an inflatable web having a linearly transverse orientation ofinflatable chambers with a central inflation region;

FIG. 5A is an example of an inflatable web having protruding structureswith a surrounding cavity;

FIG. 5B is a cross-section of the inflatable web of FIG. 5A;

FIG. 5C is a cross-section of the inflatable web based on a variation ofFIG. 5B with the cavities being connected with one another;

FIG. 6 is a cross-section of an inflatable web with inflatablesub-chambers and a tertiary ply forming a cavity that is inflatable fromthe inflation region;

FIG. 7A is a web forming apparatus;

FIG. 7B is a cross-section of a sub-chamber forming element from the webforming apparatus of FIG. 7A along cross section line A-A;

FIG. 7C is a cross-section of a nip section of the sub-chamber formingelement from the web forming apparatus of FIG. 7A along cross sectionline B-B;

FIG. 7D is a cross-section of the inflatable web moving through the webforming apparatus of FIG. 7A along cross section line C-C;

FIG. 7E is a cross-section of an attachment element from the web formingapparatus of FIG. 7A along cross section line D-D;

FIG. 7F is a cross-section of a deflation element from the web formingapparatus of FIG. 7A along cross section line E-E;

FIG. 8 is a web forming apparatus;

FIG. 9 is an explosive view of an inflatable web with inflatablesub-chambers;

FIG. 10 is a cross-section of the inflatable web having a base ply and aformed ply;

FIG. 11A is a cross-section of the inflatable web having a two-walledinflatable structure;

FIG. 11B is a cross-section of the inflatable web of FIG. 11A alongcross section line XIB-XIB;

FIG. 12A is an isometric view of an embodiment of an inflation andsealing device with a roll of the web material of FIG. 1A loaded;

FIG. 12B is a partial isometric section view of an inflation and sealingassembly of the inflation and sealing device of FIG. 12A;

FIG. 13A illustrates a series of packaging bags in a fanfoldconfiguration;

FIG. 13B illustrates a cross-section of the packaging bags of FIG. 13A;

FIG. 13C illustrates a cross-section of the packaging bags of FIG. 13A;and

FIG. 14 is a perspective view of an expansion and bagging device.

Each of the above referenced figures is arranged in accordance with atleast some embodiments of the present disclosure.

DETAILED DESCRIPTION

The present disclosure is directed to flexible structures that can beinflated and used as cushioning or protection for packaging andshipping. In the following detailed description, reference is made tothe accompanying drawings, which form a part hereof. In the drawings,similar symbols typically identify similar components, unless contextdictates otherwise. The illustrative examples described in the detaileddescription, drawings, and claims are not meant to be limiting. Otherexamples can be utilized and other changes can be made without departingfrom the spirit or scope of the subject matter presented herein. It willbe readily understood that the aspects of the present disclosure, asgenerally described herein and illustrated in the figures, can bearranged, substituted, combined, separated, and designed in a widevariety of different configurations, all of which are implicitlycontemplated herein.

Some aspects of the present disclosure are directed to packagingelements formed from packaging material. Some packaging elements formedfrom packaging material include pads and sheets, which include a singlewall. Some packaging elements formed from the packaging material includepackaging containers, which include a plurality of walls enclosing aninterior cavity for storing one or more products. Some packagingcontainers include bags and envelopes, such as mailers, which may befabricated and then filled with an item to be shipped at a later pointin time.

Some embodiments of the present disclosure include expansion walls. Someexpansion walls include expandable walls, which are in an unexpandedconfiguration and can be expanded at a later time. Some expansion wallsinclude expanded walls, which are already in an expanded configuration.Expansion walls may include one or more inflation chambers. Someinflation chambers include inflatable chambers configured to receive afluid such as, for example, air or other suitable gaseous or non-gaseousfluids. Some inflation chambers include inflated fluid-chambers.Inflated fluid-chambers may include, for example, preformed chambers(e.g., vacuformed bubbles).

The various seals described herein include a bonding material. Thebonding material includes a sticking element. The sticking elementincludes an adhesive or cohesive material to provide an adhesive orcohesive surface, respectively. A combination of adhesive and cohesivesurfaces can be used. The sticking element can be applied directly tothe exposed surface of the material by suitable known methods, or it canbe applied on a tape, such as a double-sided tape, or other suitablemethods. In some embodiments, the bonding material includespolyethylene.

As used herein, an adhesive sticking element is made of a material thatadheres to other types of surfaces, preferably such as ones that wouldbe typically be found in the vicinity of protective packaging, such asto plastic, paper, or metals. The adhesive can stick to an opposingsurface without relying on the opposing surface having the same or acomplimentary material for the stickage to take place to form aconnection between the two surfaces. Examples of suitable adhesivesinclude liquid adhesives and pressure sensitive adhesives. Pressuresensitive adhesives can be selected that stich after applying a slight,initial, external pressure to create the bond. Examples of these includewater-based, acrylic, pressure sensitive adhesives, similar to what isapplied to packaging tape, which material holds two surfaces togethersolely by surface contact, often upon a slight initial externalpressure. Examples may include dry adhesives, which typically require noactivation with water, solvent or heat, and firmly adhere to manydissimilar surfaces. Pressure sensitive adhesives can be selected thatare aggressive and/or permanently tacky at room temperature. Pressuresensitive adhesive application and use can be automated. When used inassembly, pressure sensitive adhesives that do not require setup or longcuring times can be used to save time compared to using typical liquidadhesives. Adhesion is preferably immediate with pressure sensitiveadhesives, allowing manufacturing procedures to continue uninterrupted,which can result in significant time and labor savings.

A cohesive material of a sticking element causes one surface to stick toan opposing surface by coming into contact with the same or acomplimentary cohesive substance to form the bond between the twosurfaces. Cohesives, in which opposing cohesives stick to one another,do not stick to other substances sufficiently to adhere to those othersubstances (e.g., other surfaces of the protective packaging materialthat do not have a cohesive element, surfaces of the container, surfacesof the product to be shipped, etc.), or in some cases would stick veryweakly compared to the bond they form from sticking to each other. Acohesive can be a pressure sensitive cohesive, in which pressure isrequired to activate the bond. Examples of a suitable cohesive materialfrom which the cohesive sticking elements can be made include naturaland synthetic latex-based cohesives. The cohesive material in someembodiments is applied as a liquid to the appropriate portion of theprotective packaging material, and in others is applied in other knownforms. Some types of cohesives, such as ones made with latex, is mixedwith water without additional adhesives to bond to the respective,non-cohesive, portion of the protective packaging material, and upondrying remains stuck to the exposed surface of the protective packagingmaterial to which is has been applied. In some embodiments, the cohesivematerial can be mixed with an adhesive, often applied as a liquid, ontothe protective packaging material. The adhesive can be selected so thatafter applying the cohesive and adhesive mixture onto the protectivepackaging material (e.g., onto a film ply), the adhesive evaporates,leaving the cohesive bonded to the non-cohesive protective packagingmaterial (e.g., onto a film or paper ply). One method of liquidapplication is spraying, although brushing or other suitable methods canbe used. Also, other suitable methods of applying the cohesive to thenon-cohesive material surface can alternatively be used.

Referring to FIGS. 1A-D, a flexible structure, such as a multi-plyinflatable web or protective packaging web 100 of film for inflatableprotective packaging, is provided. The inflatable web 100 includes aformed web film layer, or ply, 105. The inflatable web 100 also includesa first longitudinal edge 102 and a second longitudinal edge 104. Theinflatable web 100 includes a base web film layer, or ply, 107, having afirst longitudinal edge 106 and a second longitudinal edge 108. Thelongitudinal edges 102, 104, 106, 108 run in a longitudinal direction103 of the inflatable web 100. The longitudinal direction of the web canbe the direction that the web 100 is advanced into a processing machine.The longitudinal direction 103 can also be the direction that the web100 is fed into a processing machine, or the direction that the finishedstructure is rolled onto a storage roll after processing. A longitudinaldirection 103 can be longitudinally upstream or longitudinallydownstream. A longitudinally upstream direction 103 is a longitudinaldirection opposed to a direction of movement of the web 100 through aprocessing machine. A longitudinally downstream direction 111 is adirection that is substantially the same as a direction of the web 100through a processing machine. Generally, a longitudinal direction 103corresponds to the longest dimension of the web film layers, or plies,105,107. The base ply 107 is aligned to be overlapping and can begenerally coextensive with the formed ply 105 (as shown in FIG. 1B),i.e., at least respective first longitudinal edges 102, 106 are alignedwith each other and/or second longitudinal edges 104, 108 are alignedwith each other. According to various embodiments, the formed ply 105and the base ply 107 form a flexible inflatable web 154 having one ormore chambers configured to be filled with fluid. The flexibleinflatable web 154 includes a first side 151 and a second side 152.According to some embodiments, the inflatable structure does not includethe base ply 107 and the base ply 107 is adhered to the flexibleinflatable web 154.

In some embodiments, the layers, or plies, 105, 107, can be partiallyoverlapping with inflatable areas in the region of overlap. The plies105, 107 can be joined to define a first longitudinal edge 110 and asecond longitudinal edge 112 of the web 100. This can be done withseparate sheets or by folding over a single sheet. A longitudinal seal113 can be formed at the first longitudinal edge 110, and a longitudinalseal 115 can be formed at the second longitudinal edge 112. For example,the first longitudinal edges 102, 106 can be coupled together to formthe first longitudinal edge 110 of the web 100, and the secondlongitudinal edges 104, 108 can be coupled together to form the secondlongitudinal edge 112 of the web 100. The coupling of the respectiveedges forms an airtight seal at the first and second longitudinal edges110, 112 of the web 100.

In some embodiments, a tertiary film or tertiary ply, 109 can be sealedto the formed ply 105, thereby sandwiching the formed ply 105 betweenthe base ply 107 and the tertiary ply 109, as illustrated in FIG. 1C(see also FIGS. 5A and 5B). This can provide added rigidity to thestructure of the web 100. The tertiary ply 109 includes a firstlongitudinal edge 101 and a second longitudinal edge 117. The firstlongitudinal edges 102, 106, and 101 can be coupled together to form thefirst longitudinal edge 110 of the web 100, and the second longitudinaledges 104, 108, and 117 can be coupled together to form the secondlongitudinal edge 112 of the web 100. The coupling of the respectiveedges forms an airtight seal at the first longitudinal edge 110 and thesecond longitudinal edge 112 of the web 100. Although, in someembodiments, the first longitudinal edge 110 is not necessarily closed,but can remain open to form an inflation region 114, allowing fluid tobe injected from the side. However, in other embodiments, the firstlongitudinal edge 110 is closed, forming a closed inflation region 114,such as a channel in which a nozzle is inserted.

The web 100 can be formed from any of a variety of web materials knownto persons of ordinary skill in the art. Such web materials may include,for example, ethylene vinyl acetates (EVAs), metallocenes, polyethyleneresins such as low-density polyethylene (LDPE), linear low-densitypolyethylene (LLDPE), high-density polyethylene (HDPE), and blendsthereof. Other materials and constructions can be used. The web 100 canbe rolled on a hollow tube, a solid core, folded in a fan-folded box, orin another desired form for storage and shipment.

The various plies (e.g. 105, 107, and/or 109) can be connected viavarious seals across the expanse thereof. The seals can merely connectthe film plies or the seals can further define or allow features tofunction. For example, plies 105,107 can be connected together by seals118. Additionally or alternatively, in accordance with variousembodiments, one or more fluid holding cavities 120 are defined within aboundary formed by seals 118. The seals 118 can seal the plies 105,107together with one or more regions remaining unsealed, such as the fluidholding cavities 120. In some embodiments, the unsealed portions caninclude inflation channels 125, inflation regions 114, and an inflationchannel port 128 between the inflation channels 125 and the inflationregion 114. The seals 118 can extend from the first longitudinal edge110 to the second longitudinal edge 112, defining the variousfluid-holding cavities 120 between the film plies. In some embodiments,such as shown in FIG. 1B, the seals 118 have a generally transverseorientation. As shown in FIG. 1B, the web 100 includes a series oftransverse seals 118 disposed along the longitudinal extent of the web100 in a transverse direction. A transverse direction is a directionextending at an angle to a longitudinal direction of the web 100. Insome embodiments, the transverse direction is substantiallyperpendicular to the longitudinal direction. However, in otherembodiments, a transverse direction can be at a non-perpendicular angleto the longitudinal direction at more than zero degrees and less than 90degrees. In some embodiments, the seals 118 can be contiguous with theseals 122 that connect the edges 112. In some embodiments, the seals 118can be contiguous with the seals 124 that define the inflation region114. The second end 124 of seals 118 can be spaced a transversedimension D from the first longitudinal edge 110. The distance betweenthe first end 122 and the second end 124 defines the transverse width ofthe transverse seal 118.

Each transverse seal 118 embodied in FIG. 1B is substantially straightand extends substantially perpendicular to the second longitudinal edge112 (e.g., transversely across the film 100). It is appreciated,however, that other arrangements of the transverse seals 118 are alsopossible. It is contemplated that the transverse seal 118 can be sealedalong the entirety of its area; however, it is also contemplated thatthe transverse seal can be sealed around a periphery with its middleportion unsealed, forming a pocket in its middle portion. It is alsocontemplated that the transverse seals 118 can be sealed with alongitudinal seal 113 proximate to the second ends 124. In otherembodiments, a pair of substantially linear seals 118 can be disposed oneither side of a separation region 126, such as shown in FIG. 5A.

The transverse seals 118, as well as the sealed longitudinal edges 110,112 (which in some embodiments can be the same continuous seal), can beformed from any of a variety of techniques known to those of ordinaryskill in the art. Such techniques include, but are not limited to,adhesion, friction, welding, fusion, heat sealing, laser sealing, andultrasonic welding. The inflatable web 100 can include fluid-holdingcavities 120. The fluid-holding cavities 120 can be inflatable anddeflatable in various embodiments, (e.g., FIGS. 1A-6). In otherembodiments, the fluid-holding cavities 120 can be filled with fluidupon inflation without a mechanism to deflate the fluid-holding cavity120, aside from destroying the fluid-holding cavity 120. In someembodiments, the fluid-holding cavities 120 can be inflatable/deflatablecavities 135 having an inflation port 123. In some embodiments, thefluid-holding cavities 120 can be large cavities extending across and/oraround a number of features, such as cavities 133. In some embodiments,the fluid-holding cavities 120 can be fully isolated cavities 121 thatare filled with fluid upon formation with no deflation mechanism. Thesevarious cavities can be used separately to form inflatable webs or canbe used in any suitable combination to form the webs. Some of thesevarious embodiments are discussed in more detail below. In accordancewith various embodiments, the various cavities contain a fluid, causingthe respective web film layers defining the cavity to be maintainedapart from one another at the locations of the cavities to providecushioning. Suitable fluids can be gases such as air, carbon dioxide,nitrogen, or other suitable gases. Fluids can also be liquids or gels.The web 100 can include an inflation region 114, (e.g. a closed or openpassageway suitable to receive an injected fluid). In one example, theinflation region 114 is a longitudinal inflation channel as shown by wayof example in FIGS. 1 and 2A-B. The inflation region 114, as shown inFIGS. 1A-1D, can be a longitudinal inflation region that is disposedbetween the second end 124 of the transverse seals 118 and the firstlongitudinal edge 110 of the web 100. The longitudinal inflation region114 can extend longitudinally along the longitudinal edge 110, and aninflation opening 116 can be disposed on at least one end of thelongitudinal inflation region 114. The longitudinal inflation region 114has a transverse width. In a preferred embodiment, the transverse widthis substantially the same distance as the transverse dimension betweenthe first longitudinal edge 110 and second end 124. It is appreciated,however, that, in other configurations, other suitable transverse widthsizes can be used. In some embodiments, one or more of the inflationopenings or ports can include a one-way valve, such as those disclosedin U.S. Pat. No. 7,926,507, herein incorporated by reference in itsentirety.

In some embodiments, the fluid-holding cavities areinflatable/deflatable cavities 135 having an inflation port 123. Inaccordance with various embodiments, the cavities 135 are formed byunsealed locations between two plies of material (e.g. 107 and 105). Inaccordance with various embodiments, in the formation of cavities 135,at least one film ply (e.g. 105) includes protruding structures 137.

In accordance with various embodiments, the protruding structures 137can define a bounded three-dimensional shapes suitable for containingthe fluids. The protruding structures 137 can also be collapsible forpacking in a denser configuration than in the inflated form. Thisbounded volume can be defined in part by a complex surface protrudingfrom at least one of the plies (e.g. 105) and which is distinguishedfrom a base webbing 141 or valley of the ply. For example, when laidflat, the ply generally defines a planar form. While it is understoodthat the plies 105, 107 are flexible and therefore can define complexsurfaces across their expanse as they are bent, folded, or otherwisedeformed, when laid flat they can also generally conform to the flatsurface across their expanse, thereby generally defining a planarsurface. Even when defining a planar surface, the protruding structures137 protrude away from the generally planar surface as separate complexsurfaces, forming a plurality of individual distinct protrudingstructures in the ply. The complex surfaces forming the individualdistinct protruding structures are present even without internal airpressure. For example, as shown in FIGS. 1C, 1D, and 6, protrudingstructures 137 protrude from ply 105 away from ply 107. In embodiments,in which ply 105 includes one or more protruding structures 137, the plydefines a formed ply 105. In embodiments, in which ply 107 includes oneor more protruding structures, then ply 107 would additionally oralternatively define a formed ply. In embodiments, in which ply 107 doesnot include one or more protruding structures, then ply 107 defines abase ply 107. As discussed below, ply 107 may be a base ply in variousembodiments, but in other embodiments, ply 107 may be a formed ply. Forclarity, with respect to the examples shown in the various figures, ply107 can be provided and referred to as a base ply, and ply 105 can bereferred to as a formed ply. But, these are merely presented as examplesand a person of ordinary skill in the art would understand that bothplies 105, 107 could be formed plies or alternatively one ply is aformed ply.

In accordance with various embodiments, the structure of the protrudingstructures 137 can be defined by a three-dimensional plastic deformationin the surface of the material ply (e.g. 105), forming the complexsurface. As used herein, a plastic deformation refers to permanentdistortion that occurs when a material is subjected to tensile,compressive, bending, or torsion stresses that exceed its yield strengthand cause it to elongate, compress, buckle, bend, or twist, therebyleaving a permanent structural deformation in the material. When the plyis originally manufactured, it can have a generally uniformcross-section. The protruding structures 137 are separate plasticdeformations of the material forming the separate complex surfaces. Invarious examples, the plastic deformation is not uniform across aprotruding structure 137, thus forming the complex curve. In aparticular example, some portions of the formed ply (e.g. 105) areplastically stretched away from the generally expansive surface of thefilm and discrete locations defining the complex surfaces. In suchembodiments, on a structural level, the material of the ply would showthe polymer plastically deformed, plastically stretched, thinned, and/orpermanently physically altered (meaning the structure will not naturallyreturn to its previous shape or size) at the locations of each of theprotruding structures 137. The base ply (e.g., 107) closes the generallyopen side on the concave side of the protruding structures 137, formingthe cavity or sub-chamber 139. Multiple connected sub-chambers 139 candefine a chamber 120 as shown in FIGS. 1C, 1D, 5C, and 6.

In various embodiments, the protruding structures 137 have a perimeter143 that defines an opening to be closed by the base ply (e.g., 107). Insome embodiments, the formed ply 105 and the base ply 107 are sealedalong a portion of the perimeter of the protruding structures 137.Additionally or alternatively, the formed ply 105 and the base ply 107are sealed along an entirety of one or more of the perimeters of theprotruding structures 137. The opening has an area 147 that is less thanthe surface area of the surface forming the protruding structure 137that protrudes away from the base ply (e.g., 107). In embodiments inwhich the protruding structure 137 is formed by plastically stretching,it is the material that previously covered the opening area 147 that isplastically stretched out to form the protruding structure 137.

In accordance with various other embodiments, the structure of theprotruding structure 137 can be formed from other suitable structuresdefining the protrusion of complex surfaces from the ply. For example,the protruding structures 137 can be molded in place, avoiding theplastic deformation in the material of the ply. In another example, theprotruding structures 137 can include a second capped structure,heat-sealed or otherwise adhered to the surface of the ply. While notnecessarily enumerated herein, other suitable structures definingcomplex surfaces protruding from the ply, as would be understood by aperson of ordinary skill in the art, are also contemplated herein.

In accordance with various embodiments, the protruding structures 137can protrude from one ply, defining a single direction of chamberprotrusion, or from both plies, defining protrusions from both surfacesof the web 100. In one example, the protruding structures 137 protrudefrom one formed ply (e.g., 105), but not the base ply (e.g., 107). Insuch examples, the base ply (e.g., 107) forms a portion of the boundedcavity but is defined by its natural shape in response to the fluidpressures, whereas the protruding structure of the formed ply (e.g.,105) takes on the applied shape of the protruding structures 137. Thus,the base ply (e.g., 107) would not necessarily protrude at the locationof the cavities in the absence of internal fluid pressure. Even in thepresence of internal fluid pressure, the base ply (e.g. 107) protrudesminimally or significantly less than the protrusion of the chamber 120in the same region of the web 100. In another example, the protrudingstructures are defined in both plies but at non-opposing locations.Stated another way, in a location where a protruding structure 137 islocated in one ply, a protruding structure 137 is not located in theimmediately opposing location of the other ply. In another example,various protruding structures 137 are independently defined with bothplies at the same or similar locations such that the chambers protrudein both directions at overlapping locations of the plies. While shown ascircular as an example, it should be appreciated that the protrudingstructures 137 can include a variety of suitable shapes and dimensions.For example, the protruding structures 137 can be rectangular,triangular, oval, oblong, etc.

In contrast to traditional protective packaging that includes preformedinflated enclosures (see, e.g. bubble wrap), here, in accordance withvarious embodiments, the protruding structures 137 are closed in a waythat allows the cavities 135 defined thereby to be inflatable and/ordeflatable after the manufacturing of the web 100. For example, each ofthe cavities 135 can include an inflation port 123. A channel 125 canconnect with the inflation port 123 or similar suitable structure foradding or removing fluid to or from the cavities 135 after formation ofthe cavities 135. In some embodiments, the various cavities 135 are alsodeflatable and inflatable after the manufacturing of the web 100. Thisis in contrast to traditional protective packaging, such as bubble wrap,in which the fluid is captured in the bubbles at the time ofmanufacturing and there is no way to deflate the bubbles aftermanufacturing of the material without destroying the bubbles, in whichcase the bubbles are not refillable. In accordance with various aspectsof the present disclosure, the cavities 135 can be inflated aftermanufacture of the web 100 and after the cavities 135 of the web 100have been deflated. This can be done by injecting air into an inflationport 123 of the cavities 135.

In accordance with various embodiments, multiple cavities 135 areinflatable and deflatable, together forming a chamber 120. For example,a sub-chamber 139 can have inflation ports 123 that are interconnectedwith another sub-chamber 139 via channel 125. Together, the group ofinterconnected sub-chambers 139 forms a chamber 120 with a commoninflation channel 125 that is suitable to distribute the fluid to eachof the sub-chambers 139 through their respective ports 123. As shown byway of example in FIGS. 1A-1B, the common inflation channel 125 can be achannel that extends between a row of chambers 120 serially (i.e.daisy-chained). In another embodiment, the common inflation channel canbe a manifold that extends to each of the chambers 120 in parallel(shown by way of example in FIG. 4B, in which an orphan chamber is fedfrom the adjacent chamber in parallel). In accordance with variousembodiments, the channel 125 may extend from the inflation region 114.In some embodiments, the web 100 includes multiple chamber channels 125with each chamber channel 125 directed to separate chambers 120. Forexample, as shown in FIGS. 1A-1B, a plurality of channels 125 extendsfrom the inflation region 114. In this example, each channel extendstransversely across the material from a longitudinal inflation region114. Additionally, different groups of chambers are provided along thelongitudinal length of the web 100.

The chamber 120 is sufficiently bounded to retain a fluid after beingsealed. In some embodiments, the chamber 120 can be inflatable afterbeing formed. In some embodiments, the chamber 120 can be deflatableafter being formed. In some embodiments, the chambers 120 can pass fluidback and forth between sub-chambers even after a final seal is appliedto the chamber, preventing additional fluid from being added to thechamber. In some embodiments, the chamber 120 is also deflatable afterbeing formed and prior to being sealed.

As shown by way of example, the web 100 can include transverse rows ofchambers 120 formed from multiple sub-chambers 139, each of the chambersbeing connected to inflation region 114. In this way, fluid injectedinto the inflation region 114 can pass though the channels 125 and intothe inflation port 123 of each of the sub-chambers 139 filling thesub-chambers 139 and the chamber 120.

In accordance with various embodiments, the web 100 can have a relativefew large chambers per section (i.e. between lines of weakness discussedherein). For example, each section may have one large chamber. Inanother example, each section may have 2-5 chambers. In another example,each section may have 5-20 chambers. In other embodiments, the web 100can have a relative large number of protruding structures that may ormay not form chambers. A large number of protruding structures arereferred to as caps. The caps can be the plastically deformed protrudingstructures 137 as discussed above. For example, more than 20 plasticallydeformed protruding structures per section may be referred to as caps.

In some embodiments, the cavities 135 can be individually inflatable.For example, each cavity 135 can include an individual inflation port tothe exterior of the web 100. Such an inflation port can include aone-way valve, a sealable port, a mechanically closing port, or thelike.

In accordance with various embodiments, when the web 100 is inflated andbeing prepared to be used as protective packaging, one or more of theinflation port 123, the channel 125, or the inflation region 114 can besealed, causing at least a partial isolation in the chambers 120 and/orsub-chambers 135. Once the final seal is applied, embodiments lacking avalve are no longer sealable or deflatable. Up to this point, fluidforced into one or more of the inflation region 114, inflation port 123,the channel 125, sub-chamber 135, or chamber 120 can be forced back outand forced back in again. This allows for the material to be inflatedand then deflated to a more condensed state for easier handling andshipping. After being handled and when being prepared as protectivepackaging, the web 100 can be inflated and have the final seal applied.

In accordance with various embodiments, the inflation channel 125 can bean extended protrusion in the formed ply 105. These extended inflationchannels 125 can be made similar to the protruding structures 137discussed above. For example, these channels can have a structure thatincludes a plastic deformation in the formed ply 105. In otherembodiments, the channels 125 may be formed by an unsealed regionbetween the formed ply 105 and the base ply 107. Fluid can then passbetween the unsealed plies 105 and 107. Seals can then bound the sidesof the channels to direct fluid from one cavity to the next. In variousembodiments, the channels are significantly smaller than the chambers120 and/or the protruding structures 137.

In some embodiments, the fluid-holding cavities can be isolated cavities121 filled with fluid upon formation, such as the multiple isolatedcavities 121 shown in FIGS. 5A and 5B. The isolated cavities 121 have noinflation port and thus can only release the fluid upon destruction.Similar to the inflatable cavities 135 discussed above, the isolatedcavities are formed from a protruding structure 137 similar to thosediscussed above. As a distinction, however, the isolated cavities 121are filled when they are formed as they do not have an inflation port orconnected channel and are thus not inflatable or deflatable unlessdestroyed. An example of this structure is shown in FIG. 5A-5C. Here,plies 105 and 107 are sealed to one another along the full circumferenceof the cavities 121 without the presence of the inflation port orchannels.

In some embodiments, the isolated cavities can include intra chamberchannels 09 can have longitudinal seals along the edges 113 and 115along with a final seal along the inflation region after inflation. Eachof these outer seals enclose the region around the protruding structures137. The seals 155 hold the tertiary ply 109 to the outer surface of theprotruding structures 137. In some embodiments, the seals 155 hold thetertiary ply 109 to peaks 140 of the plurality of protruding structures137. According to some embodiments, the protruding structures 137 haveflattened peaks 140 onto which the tertiary ply 109 is sealed. Havingthe tertiary ply 109 adhered to the peaks 140 of the protrudingstructures 137, via seal 155, enables the tertiary ply 109 to have arelatively flat structure as it is disbursed over the plurality ofprotruding structures. The rigidness of the tertiary ply 109 can beaffected by the dispersion of the protruding structures 137 along formedply 105. The chains of protruding structures 137 may be parallel, may beoffset, and/or may be in other suitable configurations. According tovarious embodiments, the inflatable web 154, when inflated, has aminimum height of at least about 1 mm, 5 mm, or 10 mm, and a maximumheight of 10 mm, 15 mm, or 30 mm. It is noted, however, that theinflated inflatable web may incorporate other suitable minimum and/ormaximum heights. According to various embodiments, the inflatable web154, when inflated, has a minimum diameter of at least about 1 mm, 5 mm,or 10 mm, and a maximum diameter of 10 mm, 15 mm, or 30 mm. It is noted,however, that the inflated inflatable web may incorporate other suitableminimum and/or maximum diameters.

In embodiments, discussed below, the volume between ply 105 and ply 109and within the seals is the secondary cavity 133. Here, the secondarycavity 133 is shown containing fluid. In some examples, the fluid may beopen to atmospheric air (see e.g. FIGS. 2A-3B) or the fluid may besealed. For example, the fluid here may have been trapped at the time ofsealing the ply 109 to ply 105. In some embodiments, this cavity 133 ispassively inflatable (e.g. FIGS. 2A-3B). In some embodiments, thiscavity 133 is actively inflatable (e.g. FIGS. 5A-6) through an inflationchannel 146. In some embodiments, cavity 133 is jointly inflatableand/or jointly sealable (as shown in FIG. 5B) from the cavities 135defining by the protruding structures 137. In some embodiments, thesecondary cavity 133 can form a chamber that is separately inflatableand/or separately sealable (as shown in FIG. 5C) from the cavities 135defining by the protruding structures 137.

In various embodiments, the web 100 includes one or more separationregions 126. The separation regions 126 facilitate separation of twoadjacent web portions such as separate groups of chambers 120. Theseparation regions 126 can positioned along the inflatable chambers 135,between the inflatable chambers 135, and/or along other suitablelocation of the web 100. The separation regions 126 can be separatedsuch as by tearing the web 100 by hand or with the assistance of a toolor machine. A separation region 126 can facilitate either or both ofpartial or total separation of adjacent inflatable chambers 120. Asillustrated in FIG. 1B, the separation region 126 is positioned betweenchambers 120. In this way, chambers 120 can be easily separated from oneanother. In the embodiment of FIG. 1B, thin transverse seals 118 arearranged adjacent to the separation regions 126, on either side. Whileillustrated adjacent to the seal 118, it is appreciated that theseparation region 126 can also extend through the seal 118, or throughunattached plies 105,107,109 (as included in the particular embodiment)such as through the various inflatable cavities and the plies definingthem. In various embodiments, the separation regions 126 can includelines of weakness that can be used to separate the regions.

By way of example, FIG. 1A illustrates an explosive view of aninflatable web with inflatable sub-chambers, and FIG. 1B illustrates aninflatable web 100 with inflatable sub-chambers 139 forming multipletransverse chambers 120 that reoccur longitudinally of the length of theinflatable web 100. Each of the sub-chambers 139 in each chamber 120 isconnected by channel 125. The channel 125 also connects to inflationregion 114 for inflation or deflation of the chamber 120. In someexamples, the web shown in FIG. 1B can be made with just plies 105 and107, or the web shown in FIG. 1B can be made with more plies, such asplies 105, 107, and 109. As these are merely examples, it is appreciatedthat any suitable number of plies can be used in the formation of web100. The connected sub-chambers form chamber 120.

FIGS. 1C-1D are cross-sections of the inflatable web 100 based onanother particular embodiment of FIG. 1B. Here, web 100 includes plies105, 107, and 109. Again, these are merely examples and it isappreciated that any suitable number of plies can be used in theformation of web 100. As shown in the cross section of FIG. 1C, which istaken along the cross section line IA-IA shown in FIG. 1B, and FIG. 1D,which is taken along the cross section line IB-IB shown in FIG. 1B, theprotruding structures 137 are formed in ply 105 and sealed to base ply107 forming the sub-chambers 139. The connected sub-chambers formchamber 120. The tertiary ply 109 can be sealed to formed ply 105 at thepeaks of the protruding structures 137. The cavity defined there-betweenis a secondary cavity 133. One inflation region 114 is formed betweenplies 105 and 107. Fluid is injectable into chamber 120 via inflationregion 114. In some embodiments, the tertiary ply 109 extends acrosseach of the protruding structures 137. Alternatively, the tertiary ply109 can extend across a portion of the protruding structures 137.

FIGS. 2A-2B illustrate another example of a passively inflated cavity133. In this embodiment, the tertiary ply 109 includes openings 179 nearthe edges 101, 113 thereof. The openings 179 allow air to pass throughthe ply 109 to the cavity 133 between base ply 109 and formed ply 105.Thus, when the chambers 120 are inflated, cavity 133 can fill with fluid(e.g. atmospheric air). This limits ply 109 from adhering to ply 105 viaa vacuum there between.

FIGS. 3A-3B illustrate another example of a passively inflated cavity133. In this embodiment, the inflatable web 100 includes inflatablesub-chambers and a perforated tertiary ply 109. The perforations 177pass through the tertiary ply 109 but not the other plies. Theperforations 177 allow air to pass through the ply 109 to the cavity 133between ply 109 and formed play 105. Thus, when the chambers 120 areinflated, cavity 133 can fill with fluid (e.g. atmospheric air). Thislimits ply 109 from adhering to ply 105 via a vacuum there between.

In other examples, FIG. 4A-4D illustrate other examples of the web 100.Not all references are shown, but each of these webs can be formed inaccordance with the various structures discussed above as would beapplicable to the particular example as understood by a person ofordinary skill in the art. For example, FIG. 4A includes an inflatableweb 100 having sub-chambers 139 forming chambers 120. However, in thisexample, the chambers 120 are positioned at an angle 131 with respect tothe inflation region 114. This angle 131 can improve the deflation ofthe chambers after they are originally formed. This is discussed in moredetail below. FIG. 4A also shows the termination of chamber 129. Chamber120 terminates before traversing across the web 100 as the otherchambers 120 do. In having a chamber 129 with an early termination, agap is formed, allowing for the application of a line of weakness toform the separation region 126. FIG. 4B illustrates an inflatable web100 similar to FIG. 3A with the termination of chamber 129. FIG. 4B,however, also includes an orphan chamber 144. Here, a channel 138 canbranch off a channel 125 b or sub-chamber 139 a thereby feeding chamber144. Channel 138 then feeds the orphan chamber 144 in parallel with themain channel 125 b that feeds the next adjacent chamber 145.

FIG. 4C illustrates an inflatable web 100 having a staggered orientationof inflatable sub-chambers 139. Here, each of the sub-chambers 139 areconnected to the next adjacent sub-chamber 139 via a channel 125. Eachof the different channels leave the sub-chamber at opposite angles. Thisleaves a staggered pattern of sub-chambers 139, forming a zigzag chamberdesign. Doing this allows more sub-chambers 139 to be packaged in asingle web 100.

In FIG. 4D, the chambers 120 have a linearly transverse orientation withchannels 125 connected to a central inflation region 114 a. One set ofchannels 138 exit the inflation region in one direction and another setof channels 125 b exit the inflation region in the opposite direction.This allows for chambers 120 to extend from the inflation region in bothdirections. In such an embodiment, the final seal to seal the chambers120 would be applied on both sides of the inflation region 114 a.

In FIG. 5A, the inflatable web 100 has a fluid permeate the web 100along one or more directions 136. Here, the inflatable web 100 includesisolated cavities 121. The cavities 121 are surrounded by the secondarycavity 133. The inflation region 119 directs fluid into the secondarycavity 133. A final seal along the inflation region 119 seals the fluidinto the secondary cavity 133. FIG. 5A also illustrates segment seals153. The segment seals 153 seal the secondary cavity 133 from the linesof weakness 126. Thus, the segments of the web 100 can be torn at thelines of weakness 126 without rupturing the secondary cavity 133. FIG.5B is a cross section of the inflatable web of FIG. 5A taken along crosssection line VA-VA. FIG. 5B shows the isolated cavities 121 formed byprotruding structure 137 in formed ply 105. The seal between formed ply105 and base ply 107 isolates the cavities 121. The tertiary ply 109 isthen sealed to ply 105 at seals 155, forming the secondary cavity 133.FIG. 5C includes a variation to FIG. 5B in which the cavities areconnected to one another via intra chamber channels 166. While thecavities here are still filled with fluid at formation of the inflatableweb, the fluid can move between the connected cavities but not otherwisebe deflated without rupturing them.

In FIG. 6, cavity 133 is sealed on 3 sides, forming a cavity that isinflatable from the inflation region 114. Inflation region 114 includesan opening 181 into the cavity 133. When longitudinal seal 303 isapplied, the opening 181 is separated from the cavity 133 therebysealing cavity 133 trapping fluid therein. In this way, both chambers120 and cavity 133 are actively inflated with fluid.

The inflatable structure of the inflatable web is positioned between,and adhered to, the outer plies and maintains the outer plies at adistance between each other along an area of the inflatable web. Thisinflatable structure thus acts as an expanded internal structure betweenthe outer plies. The forces applied between the outer plies and theinternal structure provide rigidity and stiffness to the structure,causing the inflatable web to act as a framed structure, similar to anI-Beam, truss, or other similar framed structure.

As used herein, “inflated” as a verb refers to actively injecting afluid. The term “inflated” as a an adjective can describe a fluid thatwas “injected” into a chamber or cavity or the term can describe achamber or cavity occupied by a fluid regardless of whether the fluidwas injected or trapped therein, such as by the manufacturing process.

The protective packaging material described above is usable with abacking sheet to form envelopes or mailers suitable for protecting thecontents therein. The backing sheet can be layered on the exterior. Thebacking sheet can include at least one of a paperboard, polymer sheet,craft paper, or a fiberboard (e.g., a corrugated fiberboard). Mailer orenvelope is then formed as padded envelope, also known as a cushionedmailer. It can be an envelope incorporating protective padding toprotect items during shipping. Here, the web 100 can be used as thepadding.

In accordance with various embodiments, a protective packagingmanufacturing system 200, 300 suitable to form an inflatable web 100and/or inflate the web 100 into protective packaging material isprovided. In accordance with various embodiments, as illustrated inFIGS. 7A-8, web forming apparatuses 200 can include one or more elementsfor forming the expanded regions into at least one of the plies. The webforming apparatus 200 can include a film supply 210, 211 and a filmsupply 220, 221. The film supply 220, 221 dispenses formed ply 105. Thefilm supply 220, 221 directs the formed ply 105 to an extendedvolume-forming device 240. The extended volume-forming device 240 formsthe protruding structures 137 on formed ply 105. The web formingapparatus 200 also includes an attachment element 250. The attachmentelement 250 opposes the extended volume-forming device 240 and receivesthe base ply 107 from the film supply 210, 211. The attachment element250 presses the base ply 107 against the formed ply 105, while thevolume forming device 240 presses the formed ply 105 against the baseply 107. The attachment element 250 aids in sealing the plies 105 and107 together. When formed ply 105 is sealed to base ply 107, some fluidis trapped in the protruding structures 137 such that they are at leastpartially inflated. In embodiments in which the web 100 includesisolated cavities, the protruding structures 137 have all the fluid inthem that they will receive.

The sealed plies form the web 100. In some embodiments, the formation ofthe web 100 can be finished at this point. In other embodiments, atertiary film ply 109 can be added. In such embodiments, the web 100 isdirected to a second attachment device 260. An additional film supply230, 231 directs film ply 109 to the second attachment device 260. Thesecond attachment device 260 includes opposing elements 261, 262 thatpress the film ply 109 against the formed ply 105 and attaches the twotogether on top of the protruding structures 137 on the formed ply 105.The web 100 is directed to a deflation element 270. The deflationelement 270 includes opposing elements that compress the web 100,forcing at least some of the fluid contained therein out, forming thecompressed web 100 c. This compacts the web 100, making it easier tohandle or ship. A second set of processing elements 280 can also beincluded. These processing elements can remove additional fluid from theweb 100, guide the web 100 to a roll, or perform any other beneficialprocessing step. The compressed web 100 c can be directed to a storagemechanism 290 which can prepare the web for transportation or ready itfor inflation by the inflation system 300.

In accordance with various embodiments, the various film supplies 210,211; 220, 221; and 230, 231, provide the film to the system for formingthe web 100. In some embodiments, the film supply is a roll (e.g., 210,220, 230) or fanfold film supply. In some embodiments, the film can beformed at the web forming system via a film extruder (e.g. 211, 221,231). The film extruder can manufacture the film and direct the newlymade film to the forming device. The film supply 210 can additionallyinclude a guide path including rollers positioned to direct the filmappropriately.

In accordance with various embodiments, the extended volume formingdevice 240 forms the protruding structures and/or the sub-chambersdiscussed above. In one example, the forming device 240 includes anarray of chamber forming recesses 242. The chamber forming recesses 242can be included as part of a chamber-forming die. In some examples, thechamber-forming die is part of a rotating cylinder. In variousembodiments, the chamber-forming device includes at least one of athermoforming, vacuum forming, or pressure forming mechanism. In someexamples, the forming device 240 is heated to improve the forming of theprotruding structure 137. In this way, the formed ply 105 is heated bythe forming device 240 and then vacuumed or otherwise pulled into thechamber forming recesses 242 causing plastic deformation of the ply ateach of those recesses forming the protruding structures 137. In otherembodiments, the forming device 240 is heated to cause the formed ply105 to seal to the base ply 107. For example, each of the chamberforming recesses 242 includes a vacuum port 241 therein, that issuitable to apply a vacuum against the formed ply 105 positioneddirectly against the chamber-forming device 240. The film ply is pulledinto and plastically deformed to take the shape of the chamber formingrecess. In this way, the forming device 240 can plastically deform thesurface of formed ply 105, creating protruding structures 137 that candefine cavities or sub-chambers as discussed above. The chamber-formingdevice 240 can also include a channel recess 243. The channel recess canform extended channels 125 in the formed ply 105. The channels areformed by plastically deforming the film ply positioned directly againstthe chamber-forming device and plastically stretching the material tocreate a plastically deformed channel. Additionally or alternatively,the channels 125 can be formed by having the channel regions unsealed.The unsealed regions can include the chamber forming recesses and fluidpaths that extend between at least some of the chamber forming recesses.

In various embodiments, the chamber-forming device 240 can also includeadditional recesses for forming additional features in the formed ply105. For example, the chamber-forming device 240 can include a channelrecess 247. The channel recess 247 can be formed in the surface of thechamber-forming device 240. The chamber-forming device 240 can pull(e.g. via a vacuum port) the ply 105 into the channel recess 247,plastically deforming an extended channel 132. Additionally oralternatively, the chamber-forming device 240 can include an inflationregion recess 245. The chamber-forming device 240 can pull (e.g. via avacuum port) the ply 105 into the inflation region recess 245 indirection 249. While in some embodiments, the inflation region recess245 and/or the channel recess 247 may actively pull and deform theseregions of ply 105. In some embodiments, the inflation region recess 245and/or the channel recess 247 may merely lack sufficient pressure topress the ply 105 against ply 107 along these regions to form asufficient seal. Absent a seal, fluid can pass through these regions. Inthis way, the features (e.g. inflation region and/or channel) can beformed without plastic deformation.

In various embodiments, the forming device 240 can include pinch regionsthat include surfaces that have a sufficiently minimal gap withattachment element 250. For example forming device 240 can include pinchsurfaces 244, 246, and/or 248. Pinch surface 244 can form seals 118 whenheated (or the web is sufficiently hot) and pressed against attachmentelement 250. Pinch surface 246 can form seals 113 when heated (or theweb is sufficiently hot) and pressed against attachment element 250.Pinch surface 248 can form seal 115 when heated (or the web issufficiently hot) and pressed against attachment element 250. Accordingto various embodiments, the chambers remain unsealed, partially sealed,and/or held partially closed during inflation. According to someembodiments, the chambers do not need to be held closed duringinflation.

In accordance with various embodiments, the attachment element 250 aidsin attaching base ply 107 to formed ply 105. In various embodiments, theattachment element 250 is an opposing surface that is positioned closeto or against the forming device 240. The attachment element 250 canapply a pressure against the forming device 240 as the film passesbetween the two. Additionally or alternatively, the attachment element250 can apply heat to cause the sealing. Additionally or alternatively,the attachment element 250 can apply an adhesive to cause the sealing.In various embodiments, the attachment element 250 is a cylinder thatrolls against or near (forming a nipping device) a cylindrical die ofthe forming device 240. This compresses and seals the plies therebetween. This process can form the seals 118, 113, 115, etc., while alsoforming the protruding structures 137.

In accordance with various embodiments, the attachment element 260 aidsin attaching film ply 109 to formed ply 105 by forming seals 155 asdiscussed according to the embodiments above. In various embodiments,the attachment element 260 includes opposing surfaces 261 and 262 thatare positioned close to or against each other. In embodiments in whichthe cavities 121 are isolated and fluid does not escape, the opposingsurfaces may be gapped sufficiently such that they do not destroy thecavities but are sufficient to seal the tertiary ply 109 to the formedply 105. The attachment element 260 can apply a pressure betweensurfaces 261 and 262 as the film passes between the two. Additionally oralternatively, the attachment element 260 can apply heat to cause thesealing. Additionally or alternatively, the attachment element 260 canapply an adhesive to cause the sealing. In various embodiments, theattachment element 260 includes two cylinders that rolls against or near(forming a nipping device) one another, forming the sealing surfaces 261and 262. In various embodiments, the attachment element 260 includes aheating element 263 that directs heat into the plies to seal themtogether. In some embodiments, the attachment element 260 is a heateddrum that heats the ply as it comes into contact therewith.

In accordance with various embodiments, the compressing/deflationelement 270 compresses the web 100, removing some or all of the fluidcontained therein. As indicated above, fluid is or can be trapped in theweb 100 during formation of the protruding structures 137. To compactthe web 100 to make handling easier, the web can be compressed forcingthe fluid out of the inflation regions 119 and 114. When isolatedcavities 121 are formed, the deflation process can be focused atremoving fluid from the secondary cavity between ply 105 and 109 so asnot to destroy the isolated cavities. In some embodiments, the inflationregion 114 and/or 119 can be open regions, meaning there is no end sealor a discontinuous end seal 113 allowing fluid to be dispelled along thelength of the web 100. In some embodiments, seal 113 can be subsequentlyadded. For example, secondary element 280 can be a sealing element thatapplies a longitudinal seal such as 113. In one embodiment, shown inFIG. 6, a pair of compression rollers 171B, 172 a are positioned at anangle to the flow of the web 100 through the system. This angle allowsthe rollers 171B, 172 a to compress the chambers and cavities of thefilm opposite the inflation region 114 and the move toward the inflationregion 114 as the film progresses. This aids in limiting the trapping ofair by the rollers 171B and 172 a. In other embodiments, the compressionelements 171C, 172 b may be perpendicular to the flow of material, asshown in FIG. 8. FIGS. 7A-8 can be distinguished by the angle of thecompression elements relative to the movement of the web through thesystem. In some embodiments, angled compression elements (see FIG. 7A)may be suitable to remove fluid from webs that have perpendicularchambers relative to the flow of the material through the system 200.This angle relative to the chambers may limit trapping of fluid. Inother embodiments, perpendicular compression elements 171C, 172 b (seeFIG. 8) remove fluid from webs that have angled chambers relative to theflow of the material through the system 200 (see FIG. 4A or 4B). Inaccordance with various embodiments, the inflatable web supply 290receives the inflatable web after the first and second opposingdeflation elements deflate the web. The web storage stores the web in asubstantially uninflated state allowing for transportation of the web ina high-density configuration. After transportation, the web can bere-inflated for used as protective packaging.

According to some embodiments, positioned along one or more of theformed layer 105, base layer 107, and/or tertiary layer 109 is a heatresistive material 505 configured to prevent heat seals from formingbetween two layers at locations at which the heat resistive material 505is treated or positioned between the two layers. This enables channels(e.g., channels 125), chambers (e.g., chambers 135), inlets, vents, andother non-sealed formations to remain unsealed after the application ofheat to two or more of the layers 105, 107, 109. The heat resistivematerial 505 can be applied to one or more layers via suitable meanssuch as, for example, through printing, spraying, spreading, or othersuitable means. The heat resistive material 505 can be, for example, aglue, and ink, a powder, an adhesive, and/or other suitable formconfigured to be applied to one or more of the layers 105, 107, 109.

As shown in FIG. 9, the heat resistive material 505 is applied to layer107 in patterns 510, wherein every location at which the heat resistivematerial is placed on layer 107, layer 107 will not heat seal to layer105. On all untreated areas 515 of layer 107 that are not treated withthe heat resistive material 505, layer 107 can be heat sealed to anotherlayer (105 or 109) at a location that is not treated with the heatresistive material 505. The heat resistive material 505, as shown inFIG. 9, can be applied to the tertiary layer 109 in a pattern 520configured to enable the peaks 140 of the protruding structures 137 toseal against the tertiary layer 109 at the untreated areas 515 of thetertiary layer 109. Ply 109 can be applied to ply 105 in direction 201.Ply 107 can be applied to ply 105 in direction 202.

Applying the heat resistive material 505 between the formed layer 105and the second layer 109 enables the first 105 and second 107 layers tobe adhered together with the chambers 135 and channels 125 to beinflated and sealed prior to the application of the tertiary layer 109,as shown in FIG. 10.

According to various embodiments, the flexible inflatable web 154includes a plurality of walls, as shown in FIGS. 11A-11B. The pluralityof walls may be from a single ply 105 (as shown in FIGS. 11A-11B) or maybe from a plurality of plies. As shown in FIGS. 11A-11B, the base ply107 is adhered to the peaks 140 of the first side 151 of the flexibleinflatable web 154, and the tertiary ply 109 is adhered to the peaks 140of the second side 152 of the flexible inflatable web 154. As thecavities 135 expand with fluid, the base ply 107 conforms to a shapedefined by tangents from a plurality of peaks 140 of the first side 151of the flexible inflatable web 154, and the tertiary ply 109 conforms toa shape defined by tangents from a plurality of peaks 140 of the secondside 152 of the flexible inflatable web 154. The pluralities of peak mayeach or both conform to a 2-dimensional (2D) pattern. According tovarious embodiments, the outer plies 107 and/or 109 extend along aphantom first tangential surface, bridging the valleys of the acontoured surface of the flexible inflatable web 154, such that when thechambers are inflated the affixed outer ply and the inflatable webcooperatively form a framed structure having significantly elevatedbending stiffness compared to a bending stiffness resulting from theinflatable web structure absent the attached outer ply.

Turning now to FIGS. 12A-12B, an inflation and sealing device 300 (FIG.12A) having an inflation and sealing assembly 355 (FIG. 12B) forconverting the inflatable web 100 into a series of inflated walls orcushions 305 is shown. The uninflated inflatable web 100 can be a bulkquantity supply of uninflated material 310. For example, as shown inFIG. A, the uninflated inflatable web 100 can be provided as a roll 315of supply material, which can be rolled around an inner support tube325. In some embodiments, the supply material is rolled into a roll 315with a hollow center. The support tube 325 or hollow center of the roll134 of material is supported on a supply support element 330, in thiscase a roll axle, of the inflation and sealing device 300. The roll axle330 accommodates the center or tube 325 of the roll of web material 100.In other embodiments, different structures can be used to support theroll of material, such as a tray, fixed spindle or multiple rollers, ora supply material of different configuration (e.g., folded supplymaterial). In some embodiments, the web 100 is delivered from a foldedform such as a fanfolded configuration 320 (as shown in FIG. 10).

The inflation and sealing device 300 includes handling elements, witheach of the handling elements including web-supporting portions. Theweb-supporting portions support and direct an inflatable web 100 ofmaterial in a longitudinal direction 335 along a path. The handlingelements can include a supply support element 330 that supports a supply310 of the web 100 in an uninflated state. An inflation and sealingassembly 355 is operable to inflate the web 100 with a fluid bydirecting the fluid between superimposed plies 105, 107 of the web 100and to seal the plies 105, 107 together to seal the fluid therein. Twoof the web-supporting portions (e.g., a roll axle 330 and guide member340) are arranged relative to a supporting structure 345 and each othersuch that the supply material 310 experiences a different amount oftension along the transverse direction as it passes from the first tothe second web-supporting portion. The relative position of the twoweb-supporting portions causes a difference in tension in two portionsof the web 100 disposed transversely of each other in a substantiallysame longitudinal location along the path. In further embodiments of thepresent disclosure, the differential tension can be achieved byproviding the guide member 340 with one or more expansion elements asdescribed further below. In some examples, the resulting shape of theguide member 340 can be configured to define a slightly shorterlongitudinal travel distance between the first and second adjacentweb-supporting portions at one transverse end of the web as compared tothe longitudinal travel distance between the first and second adjacentweb-supporting portions at another (e.g., opposite) transverse locationof the web, as will be further described.

The web material 100 is pulled through the inflation and sealing device300 by a drive 160. In some embodiments, intermediate members such as aguide member 340 (e.g., which can include a fixed rod, or a roller) canbe positioned between the supply 310 and the drive 350. For example, theoptional guide member 340 can extend generally perpendicularly from thesupport structure 345. The guide member 340 can be positioned to guidethe web 100 away from the roll 315 of material 100 and along a materialpath 335 along which the material is processed, also referred to as alongitudinal path. The guide member 340 is arranged between the materialsupport 330, which supports the supply material, and the inflation andsealing assembly 355 components of the inflation and sealing device 300.The guide member 340 can be arranged to route the web material 100 fromthe supply toward the inflation and sealing assembly 355 such that theweb material 100 follows a curved longitudinal path. The guide member340 can include one or more surfaces, which define web-supportingsurfaces (e.g., surfaces extending along the side of the guide member340 around which the web 100 bends as it traverses the path 335). Insome examples, and as described further below, the guide member 340 caninclude one or more expansion elements. The one or more expansionelements provide at least a portion of the web-supporting surface of theguide member 340 and can configure the guide member 340 to providevariable tension on the web material 100 at different transverselocations of the web material 100.

The guide member 340, or a portion thereof, can be movably coupled tothe inflation and sealing device 300, such that the guide member 340, orthe movable portion thereof, can move (e.g., spin, translate, oscillate,etc.) in relation to the support structure 345 when the web material 100is being drawn from the roll 315 by drive the 350. In some examples, theguide member 340 includes a guide roller, which includes an axle or rodportion and a rotatable or roller portion coaxially coupled to the rodportion such that the roller portion spins about a common axis of therod and roller portions. The roller portion provides a web-supportingsurface that supports the web 100, in this case moving with the web 100as it is being drawn from the roll 315. The moving web-supportingsurface can reduce or eliminate sliding friction between the guidemember 340 and the web 100. However, in other embodiments, guide members340 with a fixed web-supporting surface are also envisioned. Forexample, the guide member can include a rod, similar to the axle,without the rotatable portion. A low friction material, such aspolytetrafluoroethylene (PTFE), can be provided (e.g., in the form of acoating or a strip of material adhered to) on at least a portion of theweb-supporting surface of a non-rotatable rod, to reduce slidingfriction. In yet other embodiments, the non-rotatable portion or rod ofthe guide member and the rotatable portion (e.g., roller) may not becoextensive. For example, the only rotating portion of the guide member340 can be the expansion element. Web-supporting surface(s) of the guidemember 340 that do not rotate as the web 100 is traveling over the guidemember 340 can be coated or otherwise provided with friction-reducingmaterial(s). In some embodiments, the guide member 340 can additionallyor alternatively be coupled to the inflation and sealing device 300 suchthat it moves in a direction normal to the longitudinal path 335traveled by the supply material.

In the embodiments, a guide member 340 according to the presentdisclosure includes one or more expansion elements. In some embodiments,the expansion element provides some or all of the web-supporting surfaceof the guide member 340. A guide member 340, according to the principlesof the present disclosure, can thus be configured to control the webmaterial 100, such as to prevent or reduce sagging of the web material100 between the roll 315 and the inflation nozzle 375 of the inflationand sealing assembly 355 of the inflation and sealing device 300.

In various embodiments, the stock material (e.g. web material 100) canadvance downstream from the supply of material, such as the roll 315,without engaging a guide roll 340, but can instead be advanced directlyinto the inflation and sealing assembly 355. As used herein, the termsupstream and downstream are used relative to the direction of travel ofthe web material 100. It is appreciated that other suitable structurescan be utilized in addition to or as an alternative to use of brakes,guide rollers, or web feed mechanisms in order to guide the web material100 toward a sealing zone 365 of the sealing assembly 355, which canform part of the sealing assembly 355. The sealing zone 365 can be apinch zone where the plies 105, 107 of the web material 100 are pinchedor compressed and simultaneously heated such that they fuse together.Inflation fluid can also be supplied in the sealing zone 365. Asindicated, because the web material 100 can sag, bunch up, drift alongthe guide roller 340, shift out of alignment with the sealing zone 365,alternate between tense and slack, or become subject to other variationsin delivery, the inflation and sealing assembly 355 may need suitableadjustability to compensate for these variations.

The web material 100 is advanced through the inflation and sealingassembly 355 by a drive 350. The inflation and sealing assembly 355 canincorporate the drive 350 or the two systems can operate independently.The drive 350 includes one or more devices operable to motivate theflexible structure 100 through the inflation and sealing device 300. Inthe embodiment shown, the drive 350 includes a backing element such asbacking wheel 360 driven by a motor via a belt. In other embodiments thedrive 350 can include a different roller, wheel or drum, or more thanone of the same. In other embodiments the backing element 360 can bestationary. In some embodiments the drive 350 can include a belt drive,where the belt is in contact with a portion of the web 100. In someembodiments, multiple belts can be used to motivate the web material 100through the inflation and sealing device 300. In other embodiments, abelt motivates the web material 100 along the material path, and one ormore rollers follow, being driven by the motion of the web material 100.In other embodiments, a combination of belts, rollers, or drums move theweb material 100 through the inflation and sealing device 300 along thematerial path 335. In some embodiments, the various belts, drums, orrollers can be driven by a single motor and be connected with otherbelts, pulleys, or gears to transfer rotational motion throughout aconnected drive. In other embodiments, the belts, drums or rollers canbe driven by individual motors or servos.

For example, in various embodiments, the drive 350 includes one or moremotor driven rollers operable to drive the flexible material 100 in adownstream direction along a material path 335. One or more of therollers or drums can be connected to the drive motor such that the oneor more rollers drive the system. In accordance with variousembodiments, the drive 350 drives the web material 100 without a beltcontacting the flexible structure. In another example, the system has abelt that does not contact the web material 100 but instead drives therollers. In another example, the system has a belt on some driveelements but not others. In another example, the system can have beltsinterwoven throughout the rollers allowing the material to be driventhrough the system by the belts.

The inflation and sealing device 300 includes an inflation and sealingassembly 355. Preferably, the inflation and sealing assembly 355 isconfigured for continuous inflation of the web material 100 as it isunraveled from the roll 315. The roll 315, preferably, comprises aplurality of inflatable chambers 135 that are arranged in series, e.g.,in a chain forming a continuous or semi-continuous web. In someembodiments, the web 100 is a singular pad having a sealed end. To beginmanufacturing the inflated cushions 305 from the web material 100, theinflation opening 116 of the web material 100 is inserted into aninflation assembly, such as an elongate guide 375 which is inserted intothe inflation channel 114 for guiding the web material through theinflation and sealing device 300. The transverse width of the inflationchannel 114 can be selected to fit around the nozzle suitably closely toslide over the nozzle 275 and allow fluid to flow into the inflatablechambers 135. In this embodiment, the elongate guide is also aninflation nozzle 375, and is advanced along the material path 335. Thenozzle 375 has an elongated portion, which includes one or more of anozzle base, a flexible portion, and/or a tip. The elongated portion canhelp guide the flexible structure 100 to a sealing zone 365. At the sametime the nozzle 375 can inflate the flexible structure through one ormore fluid outlets 380. In this embodiment, the fluid outlets 380 areopenings in the nozzle 375. The one or more fluid outlets 380 pass fromthe inflation channel 114 out of one or more of the nozzle base, theflexible portion, or the tip. The tip includes a terminal portion thatcan act as a guide to initiate guiding of the nozzle 375 into theinflation channel 114. The terminal portion is a hemispherical plug inthe embodiment shown, but other shapes are contemplated. In theembodiment shown in the figures, preferably, the web material 100 isadvanced over the inflation nozzle 375 with the inflatable chambers 135extending transversely with respect to the inflation nozzle 375 and theside outlets 380. The side outlets 380 direct fluid in a transversedirection with respect to a nozzle base into the inflatable chambers 135to inflate the inflatable chambers 135 as the web material 100 advancesalong the material path 335 in a longitudinal direction. In otherembodiments, the outlets 380 direct fluid in other directions withrespect to the nozzle base. The inflation nozzle 375 inserts a fluid,such as pressurized air, into the uninflated web material 100 throughnozzle outlets, inflating the material into inflated cushions 305. Theinflation nozzle 375 can include a nozzle inflation channel that fluidlyconnects a fluid source, which enters at a fluid inlet, with the nozzleoutlets (e.g., side outlets 380). It is appreciated that in otherconfigurations, the fluid can be other suitable pressured gas, foam, orliquid. The inflated web material 100 is then sealed by the sealingassembly 355 in the sealing zone 365 to form a chain of inflatedcushions 305. Typically a nozzle 375 has an outer diameter of about ¼ to½ of an inch. In this embodiment, the outer diameter of the nozzle isabout 3/16 of an inch. Other suitable nozzle diameters can alternativelybe selected.

The inflation and sealing assembly 355 includes a heat sealer 385 toform the longitudinal seal 303 in the web material 100 in a sealing zone365, trapping fluid between the plies 105,107 and thus forming thecushions 305. The heat sealer 385 includes opposing compression elements390, 395 in compression against each other to compress the overlappingplies 105,107 together in a sealing zone 365. The heat sealer 385includes a heating element that provides heat energy to the sealing zone365. The opposing compression elements 390, 395 and the heating elementcooperate to produce sufficient compression and heat in the compressedoverlapping plies 105,107 in the sealing zone 365 to heat seal theoverlapping plies 105,107 together, thereby sealing closed the inflatedinflatable chambers 135 and trapping the fluid. Other suitable sealerssuch as, for example, ultrasonic welders or adhesive sealers can beused.

In the embodiment shown, the compression element 395 is provided as arotary sealing element 400. The rotary sealing element 400 is positionedsuch that the compression element 395 contacts one side of the webmaterial 100 (e.g., one of the plies 105, 107) and is opposed to thecompression element 390, which contacts an opposite side (e.g. the otherof the plies 105, 107) of the web material 100 in the sealing zone 365to form the longitudinal seal 303 to trap inflation gas in theinflatable chambers 135. According to some embodiments, the rotarysealing element 400 has a relatively narrow convex portion, forming thecompression element 395 around its circumference. In FIG. 12B, forconvenience, the rotary sealing element 400 is shown partially retractedfrom the compression element 390 with respect to a sealing position.Certain components of the inflation and sealing device 300 are visiblebehind the web material 100. Transverse walls extend inwardly from theconvex portion toward the rotation axis of the sealing element 400. Inthis embodiment, the inflation nozzle 375 functions as an air injectorby discharging air (or other inflation fluid) along path 405 through theone or more outlets 380 located along the nozzle 375. In otherembodiments, an injector separate from the nozzle 375 can be used toinject inflation gas into the inflatable chambers 135. In someembodiments, the sealing element 400 includes a non-stick releasecoating to prevent sticking of the web material 100 thereon and reducefriction.

According to some embodiments, the heating element is a plug orcartridge-style heater that is electrically powered. The heating elementcan be electrically heated, for instance, by providing an electricalresistance that converts electrical energy into heat energy. The heatingelement can be powered by direct current or alternating current, whichalternating current can be one phase or three phase power. The heatgenerated in the heating element conducts, and can convect, heat fromthe heating element to the rotary sealing element 400 and to thecompression element 395.

The heating element can be any material or design suitable to sealtogether adjacent plies 105,107 together. In various embodiments theheating element can be resistive wire or foil. The wire or foil can beformed of nichrome, iron-chromium-aluminium, cupronickel or other metalssuitable for forming and operating a heating element under conditionsthat are used for sealing plies of the flexible material togetherallowing the heating element to melt, fuse, join, bind, or unitetogether the two plies 105,107. In some embodiments, the heating elementis formed from about 80% nickel and 20% chromium annealed soft. In otherembodiments, the heating element 375 can be a thin-film heater element.The thin-film heating element can be formed of barium titanate and leadtitanate composites or other materials suitable for forming andoperating the heating element under conditions that allow the heatingelement to obtain a sufficient heat to seal the plies together.

In the embodiment shown, the sealing element 400 is mounted such thatits axis is fixed relative to the support structure 345. In otherembodiments it can be mounted such that it is displaceable toward andaway from the compression element 390, either manually or by mechanicalassistance.

It may be desirable to retract the sealing element 400 away from the webmaterial 100, e.g., when operation of the inflation and sealing device300 is interrupted so as to prevent burning of the web material 100. Forexample, the position of the sealing element can be adjusted forincreasing or decreasing the pressure between the compression element395 and the compression element 390. For example, an actuator 405actuates a cam via a belt. A cam follower rides on the cam to cause thesealing element 400 to be displaced such that a spring is compressed ordecompressed to create more or less seal force, between the compressionelements 390, 395, respectively. Sealing pressure can be adjusted, forexample, to accommodate web materials 100 of different thickness,different materials, or different numbers of plies.

In the embodiment illustrated, the sealing element 400 is freewheeling,e.g., is caused to rotate by the movement of the web material 100against which the sealing element 400 is pressed. In other embodiments,as an alternative to a freewheeling sealing element 400, a motor can beprovided for rotating the sealing element 400 in coordination with theother driving mechanisms.

In some embodiments the sealing element 400 can be made from a metalsuch as aluminum, steel, brass, bronze; or other suitable material.Thus, the sealing element 400 can have an appreciable thermal mass. Forinstance, the sealing element 400 can have a sufficient thermal massmaintain a sufficiently consistent temperature to continually seal theplies 105,107 as they travel through the sealing zone 365. A temperaturesensor, such as a thermistor or thermocouple, can be supplied to senseand allow control of the temperature of the heat sealer 385. Thetemperature of the heat sealer 385 can be controlled to about 100-450°C., or preferably to 260-310° C., or more preferably to 280-290° C. Inaccordance with various embodiments, the heat sealer 385 heats up tobetween about 150° to 250° C. In some embodiments, the heat sealer 385reaches about 200° C. The peripheral portions of the heat sealer 385 canreach a lower temperature of between about 50 to 100° C.

As shown in FIG. 12B, the compression element 390 is disposed on abacking wheel 360. The compression element 390 is a resilient memberextending around the circumference of the backing wheel 360. The backingwheel 360 is driven by a motor. In other embodiments, the backing wheel360 can be freewheeling and driven by a drive wheel that frictionallyengages the compression element 390. The compression element 390includes a crown portion 410 to assist in maintaining the web material100 in a flattened state in the sealing zone 365 as it is fed throughthe inflation and sealing assembly 355. The crown portion 410 has araised rectangular profile that extends circumferentially from ashoulder portion 415 of the compression element 390. In otherembodiments, the crown portion 410 can have other profiles, such asconvex or concave profiles. The crown portion 410 has a larger radiusthan that of the shoulder portion 415. In the embodiment shown, thecompression element 390 includes two shoulder portions 415, with thecrown portion 410 disposed transversely between them. In otherembodiments, the compression element 390 can have one shoulder portion415, or can have a flat cross section such that it has no shoulderportions 415 or crown portion 410.

The compression element 390 typically is constructed of a resilientmaterial, e.g., natural rubber or a synthetic rubber such as siliconerubber. The resilient surface conforms in part to the compressionelement 395, which improves seal quality and increases seal dwell time.when the compression elements 390 and 395 are engaged and pressingagainst one another, the compression element 395 presses into the crownportion 410, distorting it into a concave profile that matches theconvex profile of the compression element 395. Non-limiting examples ofcompression elements 395 include drums, plates, wheels, boxes, and othersurfaces constructed from metal or other rigid material. The backingwheel 360 can have a resilient material applied to one or more of itssurfaces to function as a compression element 390. For example, acompression element 390 can be formed by vulcanizing a layer of rubber(e.g., ¼ inch thick) onto an aluminum or steel wheel or other backingelement. Alternatively, a compression element 390 can be preconfiguredas a resilient band and stretched over a backing element. The thicknessof the compression element 390 usually ranges from about ⅛ to about ¼inch. The resilient material should be selected such that the webmaterial 100 does not unduly stick to the compression element 390. Also,the resilient material should be selected such that it does not degradeunder heat. Suitable resilient materials often have a Shore A hardnessof from about 20 to about 95 durometer, usually from about 45 to about75, and more usually from about 50 to about 70. For example, a siliconerubber of 60 durometer may be used.

In other embodiments, the compression element 390 can be a stationaryelement that does not rotate. The surface of such a compression element390 can curve along the material path 335. The apex of the curve can belocated at approximately the center of a backing element 360, e.g.,where the sealing element 400 contacts the web material 100. The curvedsurface of the backing element 360 effectively lengthens the path of theweb material 100, which helps to compensate for dimensional changes inthe web material 100 as it is processed. In particular, the length ofthe web material 100 is decreased somewhat as the inflatable chambers135 are inflated (due to expansion of the web material 100 in thethickness direction). However, the edge portion of the web material 100that is sealed by the heat sealer 385 is not inflated, and thus thelength of the edge portion is not decreased as the inflatable chambers135 are inflated. As a result, the edge portion of the web material 100is prone to gathering as the inflatable chambers 135 are inflated, e.g.,in an “accordion” fashion. The curved surface of the backing element 360increases the length of the material path 335, which assists inmaintaining the web material 100 in a flattened state as it is fedthrough the inflation and sealing assembly 355.

The inflation and sealing device 300 includes a cutting assembly 420 tocut the web material 100. The cutting assembly 420 includes a cutter 425positioned to cut open the inflation channel 114 from the nozzle 375.The cutter 425 can be include stationary or rotating cutting element.The cutter 425 can be sharp, typically cutting by slicing; abrasive,cutting by abrasion; or another suitable cutting mechanism.

As shown in FIG. 12B, the cutter 425 is a blade with a sharp cuttingedge 430 that is sufficiently sharp to cut the web material 100 as it isdrawn past the cutting edge 430 along the material path 335. The cuttingassembly 420 in this embodiment is positioned to cut the web 100 at atransverse location between the first longitudinal edge 110 and theinlet channel 125 of the inflatable chambers 135, but in alternativeembodiments, other positions, such as positions about the inflationnozzle 375, can be employed. The cutter 425 cuts the web material 100 toopen the inflation channel 114 of the web material 100 and allow the webto come off the inflation nozzle 375. In various embodiments, theinflation channel 114 of the web 100 can be central to the web 100 or inother locations, and the configuration of the inflation, sealing, andcutting mechanisms are altered accordingly.

The cutter 425 cuts the web material 100 at a cutting location 435 wherethe cutting edge 430 is adjacent to an exterior if the nozzle 375. Atthe cutting location 435, the cutting edge 430 faces upstream and seversthe web material 100 as it moves along the path 335 past the cuttinglocation 435 so the inflation channel 114 can come off the nozzle 375.In this embodiment, as shown in FIG. 12B, the cutter 425 protrudes intothe interior of the nozzle 375 via a cutter receiving aperture 440formed in the nozzle 375. As shown, the cutter receiving aperture 440can be provided as a cutter receiving slot.

According to various embodiments, the inflatable web 100 may be in awall or cushion formation 305, as shown in FIGS. 12A-12B, or may be in apouch or C-fold bag formation 445 (as shown in FIGS. 13A-13C), or othersuitable formation.

As shown in FIGS. 13A-13C, a series of packaging bags 445 in a fanfoldconfiguration 320 (FIG. 13A), and a cross-section (FIG. 13B) of aplurality of the packaging bags 445 along the cross-section lineXIIIA-XIIIA of FIG. 13A, and a cross-section (FIG. 13C) of a packagingbag 445 along the cross-section line XIIIB-XIIIB of FIG. 13A, areillustratively depicted.

As shown, each of the packaging bags 445 includes an opening 450 intowhich one or more products/objects can be inserted. The series ofpackaging bags 445 includes an inflation channel 114 configured toenable air to pass through the packaging back 445 on one side, flowaround the C-fold, and reach the other side, inflating both a front andrear side of each of the packaging bags 445. According to an embodiment,each of the packaging bags 445 in the series of packaging bags 445includes one or more separation regions 126 configured to enable eachpackaging bag 445 to be separated from an adjacent packaging bag 445.

As described above, the web 100 may be configured as various types ofpackaging material, including bags. According to the embodiments shownin FIG. 14, a bagging machine 600 may be configured to receive a web 100of preformed packaging bag formations 445 and be configured to open theopening 450 in each bag formation in order to access the interior cavity460 of each bag formation 445.

In the embodiment of FIG. 14, the bagging machine 600 includes aplurality of fingers 605 and/or telescopic projections 610 configured topull open the bag opening 450, enabling one or moreproducts/objects/etc. to be inserted into the interior cavity 46.

The web 100 is fed into the bagging machine 200 in an unexpanded,high-density configuration. The web 100, at the supply side of thebagging machine 200, may be in a fanfold supply configuration 320 and/orother suitable configuration such as, for example a roll configuration315 (as shown in FIG. 12A).

The bagging machine 600 includes an expansion device 615. According tovarious embodiments, the expansion device may be the inflation andsealing device 300, as shown in FIGS. 12A-12B, and/or other suitablesystems/apparatuses for expanding/inflating the web 100. The expansiondevice 615 can include a heating element, heating coil, air compressor,hot air applicator, radiofrequency radiation generator, UV lightapplicator, chemical reaction applicator, pressure mechanism, or othersuitable device for expanding and sealing the web 100 including, but notlimited to, an inflation device configured to inject fluid to expand andfill the fluid-chambers 135, 133. The fluid may be air or other suitablefluids. In some embodiments, the expandable element of the web 10includes one-way valves to retain the fluid in the chamber. For example,in some embodiments, inlets 128 and 146 in FIGS. 1A-6 can be configuredto be one-way valves. In other embodiments, inlets 128 and 146 in FIGS.1A-6 can be configured to be two-way valves. In some embodiments, theinflatable chambers require a longitudinal seal to be applied. In someembodiments, the expansion mechanism 615 is positioned and configured toexpand the expandable element prior to inserting a product into theinterior cavity 460. In other embodiments, the expansion mechanism 615is positioned and configured to expand the web 100 subsequent toinserting a product into the interior cavity 460. In yet otherembodiments, the expansion mechanism 615 is positioned and configured toexpand the web 100 during the inserting of a product into the interiorcavity 460.

As shown in FIG. 14, the expansion device 615 is positioned upstreamfrom a bagging mechanism to deliver the web 100 to the baggingmechanism. The bagging mechanism is configured to seal and separate bagformations from subsequent bag formations, forming individual bags.

In other embodiments, the expansion device 615 is positioned at ordownstream from the bagging mechanism in order to cause the walls of theweb 100 to expand at other points during the bag-making process.

According to some embodiments, the expansion mechanism 615 is configuredto expand the web 100 prior to opening the bag opening 450 for insertionof one or more products into the interior cavity 460. In otherembodiments, the expansion mechanism 615 is configured to expand the web100 at the same time as or after opening the bag opening 450 forinsertion of one or more products into the interior cavity 460.

The web 100 includes one or more regions of weakness 126 and one or moreopenings 460, applied prior to the sealing process. In otherembodiments, the one or more regions of weakness 126 and/or one or moreopenings 450 are applied during or after the sealing process. Theregions of weakness 126 are configured to be broken in order to separateone packaging container from a subsequent packaging container. Theopenings 450 are configured and positioned to enable access to theinterior cavity 46 of a packaging container formation 445 and may beopened by the mechanical fingers 605 and/or suction cups 620.Pressurized air can be used to aid in opening the opening 450 in thepackaging container formations 445.

According to some embodiments, the fingers 605 are configured to pinch aportion of the packaging container opening 450, providing furthersecuring means of opening up the packaging container at the opening 450and holding the packaging container in place. The bagging machine 600can include an air blower 625 configured to apply air pressure to theopening 450 to aid in opening the packaging container. The opening 450can include a pouch seal. The pouch seal can include an adhesive forsealing closed the opening 450 once product is inserted. Other forms ofsealing the opening 450, such as heat sealing, can, additionally oralternatively, be implemented. Once the opening 450 is closed andsealed, the regions of weakness 126 can be broken by suitable means suchas, for example, reversing the next packaging container, cutting,melting, or other suitable means.

Each packaging container 445 in the web 100 can be separated using apulling force applied to each packaging container 445, tearing theregion of weakness 126 located between each bag in the series of bags,or using one or more cutting edges configured to form a laceration alongthe seam connecting two packaging containers 445 in the series ofpackaging containers 44. In some embodiments, each bag in the series ofbags is separated using focused heat configured to melt a portion of theseam connecting two packaging containers 445 in the series of packagingcontainers 445.

In some embodiments, a bagging machine is configured to both convert andseal the web 100 into one or more completed packaging containers. Theweb 100 is fed into the bagging machine in an expanded or unexpandedconfiguration and can be in a roll configuration, fanfold configuration,or one or more other suitable configurations.

Once fed into the bagging machine, the web 100 passes through anexpansion device such as, for example, expansion mechanism 615,configured to inflate the chambers of the web 100. According to someembodiments, a section of the web 100 is left unexpanded to facilitatefolding of the web 100. In some embodiments, lines of the web 100 can beleft free of inflatable chambers to form natural hinge lines or regionsthat are more easily bent than inflated regions. In some embodiments,pressure is applied to the chambers during or subsequent to inflation,forming hinge lines or regions that are more easily bent than otherregions.

The expanded web 100 proceeds to be fed through a folding apparatusconfigured to fold the web 100 such that the longitudinal edges of theweb 100 come into contact with each other. The folding apparatus mayinclude one or more folding bars configured to fold the web 100 into aC-fold formation. The folding apparatus may further include a cross-baror other suitable device configured to align the web 100 such that thefolded web 100 forms an interior cavity. Once folded, a series ofretaining mechanisms can hold open the web 100, enabling one or moreproducts to be placed into the interior cavity 460 in, for example, aside-loading configuration. The web 100 can, for example, be positionedvertically while the product is placed into the interior cavity 460. Inother embodiments, the web can be positioned horizontally or at anothersuitable angle (e.g., with the opening to the interior cavity 460 facingupwards).

Once the product is placed into the interior cavity 460, the web 100 isfed to a sealing mechanism configured to seal the longitudinal seal andtransverse seals of the web 100. The sealing mechanism can be configuredto apply heat, pressure, and/or other suitable means of setting theseals. In some embodiments, the sealing mechanism is configured to pullthe web through the bagging machine for sealing. Once sealed, the web100 is converted into a formed and sealed bag. According to someembodiments, the bagging machine includes a separating mechanismconfigured to separate a bag from the web 100. In some embodiments, theseparating mechanism is configured to pull on the completed bag, tearingthe completed bag from a subsequent bag along a region of weakness 126.In some embodiments, the separating mechanism is configured to separatethe bag via cutting via a blade or heat. In some embodiments, theseparating mechanism may incorporate other suitable means of separation.According to some embodiments, the separating mechanism is configured tohold the bag in place to enable the sealing mechanism to seal asubsequent bag.

Examples of components that may be utilized within an inflation andsealing device 300, including without limitation, the nozzle, blower,sealing assembly, and drive mechanisms, and their various components orrelated systems may be structured, positioned, and operated as disclosedin any of the various embodiments described in the incorporatedreferences such as, for example, U.S. Pat. Nos. 8,061,110; 8,128,770;U.S. Patent Publication No. 2014/0261752; and U.S. Patent PublicationNo. 2011/0172072 each of which is herein incorporated by reference. Eachof the embodiments discussed herein may be incorporated and used withthe various sealing devices of the incorporated references and/or otherinflation and sealing devices. For example, suitable mechanismsdiscussed herein and/or in the incorporated references may be used inthe inflation and sealing of flexible structure 100.

The present disclosure is not to be limited in terms of the particularexamples described in this application, which are intended asillustrations of various aspects. Many modifications and examples can bemade without departing from its spirit and scope, as will be apparent tothose skilled in the art. Functionally equivalent methods andapparatuses within the scope of the disclosure, in addition to thoseenumerated herein, will be apparent to those skilled in the art from theforegoing descriptions. Such modifications and examples are intended tofall within the scope of the appended claims. The present disclosure isto be limited only by the terms of the appended claims, along with thefull scope of equivalents to which such claims are entitled. It is alsoto be understood that the terminology used herein is for describingparticular examples only, and is not intended to be limiting.

With respect to the use of substantially any plural and/or singularterms herein, those having skill in the art can translate from theplural to the singular and/or from the singular to the plural as isappropriate to the context and/or application. The varioussingular/plural permutations may be expressly set forth herein for sakeof clarity.

It will be understood by those within the art that, in general, termsused herein, and especially in the appended claims (e.g., bodies of theappended claims) are generally intended as “open” terms (e.g., the term“including” should be interpreted as “including but not limited to,” theterm “having” should be interpreted as “having at least,” the term“includes” should be interpreted as “includes but is not limited to,”etc.).

It will be further understood by those within the art that if a specificnumber of an introduced claim recitation is intended, such an intentwill be explicitly recited in the claim, and in the absence of suchrecitation, no such intent is present. For example, as an aid tounderstanding, the following appended claims may contain usage of theintroductory phrases “at least one” and “one or more” to introduce claimrecitations. However, the use of such phrases should not be construed toimply that the introduction of a claim recitation by the indefinitearticles “a” or “an” limits any particular claim containing suchintroduced claim recitation to examples containing only one suchrecitation, even when the same claim includes the introductory phrases“one or more” or “at least one” and indefinite articles such as “a” or“an” (e.g., “a” and/or “an” should be interpreted to mean “at least one”or “one or more”); the same holds true for the use of definite articlesused to introduce claim recitations. In addition, even if a specificnumber of an introduced claim recitation is explicitly recited, thoseskilled in the art will recognize that such recitation should beinterpreted to mean at least the recited number (e.g., the barerecitation of “two recitations,” without other modifiers, means at leasttwo recitations, or two or more recitations).

Furthermore, in those instances where a convention analogous to “atleast one of A, B, and C, etc.” is used, in general such a constructionis intended in the sense one having skill in the art would understandthe convention (e.g., “a system having at least one of A, B, and C”would include but not be limited to systems that have A alone, B alone,C alone, A and B together, A and C together, B and C together, and/or A,B, and C together, etc.). In those instances where a conventionanalogous to “at least one of A, B, or C, etc.” is used, in general sucha construction is intended in the sense one having skill in the artwould understand the convention (e.g., “a system having at least one ofA, B, or C” would include but not be limited to systems that have Aalone, B alone, C alone, A and B together, A and C together, B and Ctogether, and/or A, B, and C together, etc.). It will be furtherunderstood by those within the art that virtually any disjunctive wordand/or phrase presenting two or more alternative terms, whether in thedescription, claims, or drawings, should be understood to contemplatethe possibilities of including one of the terms, either of the terms, orboth terms. For example, the phrase “A or B” will be understood toinclude the possibilities of “A” or “B” or “A and B.”

As will be understood by one skilled in the art, for any and allpurposes, such as in terms of providing a written description, allranges disclosed herein also encompass any and all possible subrangesand combinations of subranges thereof. Any listed range can be easilyrecognized as sufficiently describing and enabling the same range beingbroken down into at least equal halves, thirds, quarters, fifths,tenths, etc. As a non-limiting example, each range discussed herein canbe readily broken down into a lower third, middle third and upper third,etc. As will also be understood by one skilled in the art all languagesuch as “up to,” “at least,” “greater than,” “less than,” and the likeinclude the number recited and refer to ranges which can be subsequentlybroken down into subranges as discussed above. Finally, as will beunderstood by one skilled in the art, a range includes each individualmember. Thus, for example, a group having 1-3 items refers to groupshaving 1, 2, or 3 items. Similarly, a group having 1-5 items refers togroups having 1, 2, 3, 4, or 5 items, and so forth.

As will be understood by one skilled in the art, for any and allpurposes, all references to order, (e.g., first, second, third), areonly used for identification purposes to aid the reader's understandingof the present invention, and do not create limitations, particularly asto the position, orientation, or use of the invention. Such recitationsof order do not limit the scope of disclosure in any way, and elementsmay be claimed with such references in any order without departing fromthe present disclosure.

While various aspects and examples have been disclosed herein, otheraspects and examples will be apparent to those skilled in the art. Thevarious aspects and examples disclosed herein are for purposes ofillustration and are not intended to be limiting, with the true scopeand spirit being indicated by the following claims.

1. A protective packaging web, comprising: a flexible inflatable webthat includes inflatable chambers having inlets and configured forreceiving a fluid from the inlets and sealing the fluid therein, theinflatable chambers being configured such that, when inflated, theinflatable web structure has a first contoured exterior surfaceincluding a plurality of peaks and valleys, with the peaks defining aphantom first tangential surface connecting the plurality of peaks; anda flexible first outer ply affixed to the peaks and detached from thevalleys of the first contoured surface, such that when the inflatablechambers are inflated, the first outer ply extends along the phantomfirst tangential surface, bridging the valleys of the first contouredsurface, such that when the chambers are inflated the affixed firstouter ply and the inflatable web cooperatively form a framed structurehaving significantly elevated bending stiffness compared to a bendingstiffness resulting from the inflatable web structure absent theattached first outer ply.
 2. The protective packaging web of claim 1,wherein the inflatable web structure includes first and second overlayedchamber plies with a seal pattern therebetween that provides thecontoured surface when the inflatable chambers are inflated.
 3. Theprotective packaging web of claim 2, wherein the first chamber plydefines the first contoured surface, and the second chamber ply is asecond outer ply that cooperates with the first outer ply and firstchamber ply to provide the framed structure.
 4. The protective packagingweb of claim 2, wherein the second surface is configured to define asecond contoured exterior surface when the inflatable chambers areinflated on an opposite major side of the inflatable web structure fromthe first contoured surface.
 5. The protective packaging web of claim 4,further comprising a flexible second outer ply affixed to the peaks anddetached from the valleys of the first contoured surface including aplurality of peaks and valleys, wherein the plurality of peaks of thesecond contoured surface define a phantom second tangential surfaceconnecting the plurality of peaks, such that when the inflatablechambers are inflated, the second outer ply extends along the phantomsecond tangential surface, bridging the valleys of the second contouredsurface, thereby cooperatively increasing the bending stiffness of theframed structure.
 6. The protective packaging web of claim 1, wherein adistance along the first contoured surface between the peaks thereof towhich the first outer ply is affixed is greater than a distance alongthe first outer ply between the peaks to which the first outer ply isaffixed.
 7. The protective packaging web of claim 1, wherein theprotective packaging web with the inflatable chambers inflated has aplank configuration that is naturally biased to retain a flatconfiguration with the first and second outer plies extending generallyflat.
 8. The protective packaging web of claim 1, wherein the peaksinclude a multitude of peaks arranged in a 2D pattern over the firstcontoured surface.
 9. The protective packaging web of claim 1, wherein:the inflatable chambers include a plurality of protruding structures,each of the plurality of protruding structures including a baseperimeter enclosing an open base region and an extended surfaceprotruding from a plane defined by the flexible inflatable web in agenerally flat state, the protruding structures having a larger surfacearea than the open base region, forming a series of cavities, and eachof the plurality of protruding structures includes an inflation portallowing each of the plurality of cavities to be inflated via theinflation port.
 10. The protective packaging web of claim 9, wherein thesurface of the protruding structures is formed at least in part by aplastically stretched portion of the flexible inflatable web.
 11. Theprotective packaging web of claim 1, wherein each of the inflatablechambers extends along the flexible inflatable web at anon-perpendicular angle to a longitudinal edge of the flexibleinflatable web.
 12. The protective packaging web of claim 1, wherein theflexible inflatable web and the flexible first outer ply form secondaryinflatable chambers therebetween having inlets and configured toreceiving a fluid from the inlet and sealing the fluid therein.
 13. Theprotective packaging web of claim 12, further comprising one or moreventing components between the flexible inflatable web and the flexiblefirst outer ply configured to enable fluid to be removed from the one ormore secondary inflatable chambers.
 14. The protective packaging web ofclaim 1, wherein the flexible first outer ply extends along a length ofthe flexible inflatable web.
 15. The protective packaging web of claim1, further comprising a channel connecting to the inlet, the channelforming a fluid path formed within the flexible inflatable web, whereinthe inlet allows fluid to flow out of the inflatable chambers and backinto the inflatable chambers such that the inflatable chambers can becollapsed to a substantially uninflated state and subsequently returnedto an inflated state.
 16. The protective packaging web of claim 15,wherein the inflatable chambers are configured to receive a longitudinalseal adjacent thereto such that the longitudinal seal closes off theinlets, preventing the inflatable chambers from being inflated ordeflated.
 17. The protective packaging web of claim 1, wherein theflexible first outer ply is configured to be affixed to the flexibleinflatable web via heat seals.
 18. The protective packaging web of claim17, further comprising a heat resistive material affixed to one or moreof the flexible first outer ply and the flexible inflatable web, whereinthe heat resistive material prevents the first outer ply to be heatsealed to the flexible inflatable web at locations at which the heatresistive material is positioned between the flexible first outer plyand the flexible inflatable web.
 19. A method for forming an inflatableweb, comprising: providing a flexible inflatable web that includesinflatable chambers having inlets and configured for receiving a fluidfrom the inlet and sealing the fluid therein, the inflatable chambersbeing inflated, and the inflatable web structure having a firstcontoured exterior surface including a plurality of peaks and valleys,with the peaks defining a phantom first tangential surface connectingthe plurality of peaks; and affixing a flexible first outer ply to thepeaks of the first contoured surface while the inflatable chambers areinflated and the inlets are yet unsealed, such that the first outer plyis detached from the valleys and the first outer ply extends along thephantom first tangential surface, bridging the valleys of the firstcontoured surface, such that when the chambers are inflated the affixedfirst outer ply and the inflatable web cooperatively form a framedstructure having significantly elevated bending stiffness compared to abending stiffness resulting from the inflatable web structure absent theattached first outer ply.
 20. The method of claim 21, further comprisingholding the inlets at least partially closed to retain the fluid in theinflated chambers, wherein the first flexible ply is affixed to thepeaks while the inlets are held closed.
 21. The method of claim 20,wherein the inlets are held closed by pinching.
 22. The method of claim19, wherein the flexible outer ply is affixed to the peaks by heatsealing.
 23. The method of claim 22, further comprising applying a heatresistive material to one or more of the flexible first outer ply andthe flexible inflatable web, wherein the heat resistive materialprevents the first outer ply to be heat sealed to the flexibleinflatable web at locations at which the heat resistive material ispositioned between the flexible first outer ply and the flexibleinflatable web.
 24. The method of claim 19, wherein the contouredsurface is formed at least in part by a plastically stretched portion ofthe first film ply.